Gear Box Insp

PRESENTED BY MR.
TINKU SAHA
(SR. SURVEYOR OF QUEST KOLKATA)
Introduction of the Inspection call

M/S. Premium Transmission Limited.
1.0
Customer
2.0
Item description
GEAR BOX (Export Quality)
3.0
Qty
01 no.
4.0
PO no
M/S. IS International to PTL

PO 1412223 Date: 20.01.2015
5.0
Schedule date of inspection
17.02.2015
6.0
Special instructions
Nil
7.0
Selection of surveyor
Mr. Tinku Saha
Skill level on
Familiar with all type of measuring Instruments related

to Gear Box Inspection. Awareness
of geometrical
2
parameters. Inspection experience
of Gear Box
Components.
8.0
End Customer M/s. IS International.
Planning for inspection

1.0
Approved drawing
2.0 Approved QAP
U311-2000-0040-01, REV. 0
QAP/STD/14/01
Cases of Gear Boxes rejection due to
3.0 Past performance or feedbacks
dimensional error and incorrect Gear

Ratio.
4.0 Samples
100%
5.0 Workmanship standards
As per approved Drawing
6.0 Check lists
As per approved 3QAP & Drawing

parameters
Review of Supplier submitted

Documents
1.0 Supplier internal IR
59806/2013-15 & 21/PTL/15-16
2.0 Material Test Certificates
PTL compliance certificate
3.0 NDT Reports
NA
4.0 Painting Report
NA
5.0
Calibration certificates of measuring

instruments
6.0 Accept/ Reject/ rework/ Hold
Verified and found in order. History chart

Attached.
Accepted.
Visual Examination
1.0 Identification
SL NO. HGF-46352
2.0 Orientations
Orientations have been checked on assembled Gear Box

and found as per drawing.
3.0 Surface preparations
4.0 Shade of finish
5.0
Casting defects
6.0 Overall fitting and assembly
NA
Light Grey final Paint condition, where DFT measured

and found more than 150 Microns. Requirement is 100
micron (min). But As per QAP Painting checking was not
Quest scope of work. Checking DFT for Value addition.
It is a final inspection call and PTL offered assembled
Gear box after final painting. No casting defect could not
visualized due to final painting.
Found as per Drawing.
5
7.0 Sharp edges and corners removed Checked visually and found no sharp edges.
Dimensions
Tolerance and specified values
As per Drawing
(U311-2000-0040-01, REV. 0)
2.0
Measured dimensions
Reviewed internal IR (IR no. 21/PTL/15-16)

tallying with the drawing and cross checked.
Dimensions, found within Drawing limit of
tolerances.
3.0
Using measuring instruments
Vernier caliper, Micrometer,

Steel scale and Elco meter.
4.0
Shaft handing and rotation
P1, RHB, CW
5.0
Gear ratio
Gear ratio checked manually and

6
found 34.68:1 instead of 34.7 : 1.
1.0
Performance Test Witnessing

1.0
Sample size
100%
2.0
Run test
No load trial run test by test bed motor

(11 KW)
Duration of run test
As per QAP no load trial run test should

be 2 hours (min). But as it is a export
quality job so run test Conducted more
than 2 hours. (2 hours and 45 min).
4.0
Type of or scope of tests
Noise level, Vibration (Vertical,

Horizontal & Axial), Oil temp. rise,
Excessive bearing Hammering, knocking
and oil leakage.
5.0
Procedure
As per QAP
6.0
Specified values/tolerances
As per QAP
3.0
Performance Test Witnessing
7.0
Actual values/Observations
Noise level
Specified Noise level 85 dBA max (At one meter distance)
Observed 78.5dBA with surrounding noise, found within limit.
Vibration (Vertical / Horizontal / Axial)
Specified 4.5 mm/Sec Max.
Observed 1.36 / 0.87 / 2.41 mm/Sec, found within limit.
Oil temp rise
Specified Amb + 45 0 C
Observed 29 + 9 0 C, found within limit.
No excessive bearing Hammering and knocking has been
observed during performance test.
No oil leakage or Seepage has been observed during and
after completion of the performance test
8.0
Using measuring instruments
Digital Vibration meter, Sound level meter, Infrared

thermometer and hand Techometer
9.0
Accept /Reject /Hold /rework
Accepted
Generation of Inspection Report

1.0 Report no
QR/KOL/1621/1502/0610/010 Date: 17.02.2015
2.0 Selection of format
Quest format
3.0 Calibration status due date
As per attached History chart
4.0 Specified values with tolerances
Drawing No. U311-2000-0040-01, REV. 0 and

QAP no. QAP/STD/14/01
5.0 Actual values
Recorded in Report No. 21/PTL/15-16
6.0 Sample size in numbers/Sampling plan
100 %
7.0 Sample selection procedure
NA
8.0 Status : Accept /reject /hold /rework
Accepted
Visuals
At the time of the inspection

10
CHECKING DIMENSIONS
MANUALLY GEAR RATIO CHECKING
CHECKING PAINTING DFT
VIBRATION CHECKING
TACKING RPM READING
TEMP RISE MEASURED AT INPUT SHAFT AREA
NOISE LEVEL MEASURED
STAMPING ON OUTPUT SHAFT OF THE INSPECTED GEAR BOX FOR IDENTIFICATION
Thank you

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PRESENTED BY MR.

Introduction of the Inspection call

GEAR BOX (Export Quality)

M/S. IS International to PTL

Schedule date of inspection

Mr. Tinku Saha

Familiar with all type of measuring Instruments related

End Customer M/s. IS International.

Planning for inspection

2.0 Approved QAP

3.0 Past performance or feedbacks

dimensional error and incorrect Gear

5.0 Workmanship standards

As per approved Drawing

6.0 Check lists

As per approved 3QAP & Drawing

Review of Supplier submitted

59806/2013-15 & 21/PTL/15-16

2.0 Material Test Certificates

PTL compliance certificate

3.0 NDT Reports

4.0 Painting Report

Calibration certificates of measuring

6.0 Accept/ Reject/ rework/ Hold

Verified and found in order. History chart

Orientations have been checked on assembled Gear Box

3.0 Surface preparations

4.0 Shade of finish

6.0 Overall fitting and assembly

Light Grey final Paint condition, where DFT measured

Reviewed internal IR (IR no. 21/PTL/15-16)

Using measuring instruments

Vernier caliper, Micrometer,

Shaft handing and rotation

Gear ratio checked manually and

Performance Test Witnessing

No load trial run test by test bed motor

Duration of run test

As per QAP no load trial run test should

Type of or scope of tests

Noise level, Vibration (Vertical,

Performance Test Witnessing

Using measuring instruments

Digital Vibration meter, Sound level meter, Infrared

Accept /Reject /Hold /rework

Generation of Inspection Report

QR/KOL/1621/1502/0610/010 Date: 17.02.2015

2.0 Selection of format

3.0 Calibration status due date

As per attached History chart

4.0 Specified values with tolerances

Drawing No. U311-2000-0040-01, REV. 0 and

5.0 Actual values

Recorded in Report No. 21/PTL/15-16

6.0 Sample size in numbers/Sampling plan

7.0 Sample selection procedure

8.0 Status : Accept /reject /hold /rework

At the time of the inspection

MANUALLY GEAR RATIO CHECKING